Process for winding a web substrate

Abstract

A process for adjusting a property of a web substrate is disclosed. The steps include: (a) providing a nip load profile; (b) providing a calender load profile; (c) providing a desired first physical characteristic of the web substrate; (d) providing a desired second physical characteristic of the convolutely wound product; (e) winding the web substrate to form the convolutely wound product; (f) measuring an actual first physical characteristic of the web substrate; (g) comparing the actual first physical characteristic and the desired first physical characteristic; (h) adjusting the calender load profile according to the comparison of the actual first physical characteristic and the desired first physical characteristic; (i) measuring an actual second physical characteristic of the convolutely wound product; (j) comparing the actual second physical characteristic and the desired second physical characteristic; and, (k) adjusting the nip load profile according to said comparison of the actual second physical characteristic and the desired second physical characteristic.

1. A process for adjusting a property of a web substrate forming a convolutely wound product, said process comprising the steps of:
 (a) providing a nip load profile; 
 (b) providing a calender load profile; 
 (c) providing a desired first physical characteristic of said web substrate in at least one location of said web substrate; 
 (d) providing a desired second physical characteristic of said convolutely wound product; 
 (e) winding said web substrate to form said convolutely wound product; 
 (f) measuring an actual first physical characteristic of said web substrate at said at least one location; 
 (g) comparing said actual first physical characteristic and said desired first physical characteristic; 
 (h) adjusting said calender load profile according to said comparison of said actual first physical characteristic and said desired first physical characteristic; 
 (i) measuring an actual second physical characteristic of said convolutely wound product; 
 (j) comparing said actual second physical characteristic and said desired second physical characteristic; and, 
 (k) adjusting said nip load profile according to said comparison of said actual second physical characteristic and said desired second physical characteristic. 
 
   
   
     2. The process of  claim 1  wherein said adjusted calender load profile is provided as step (b). 
   
   
     3. The process of  claim 1  wherein said adjusted nip load profile is provided as step (a). 
   
   
     4. The process of  claim 1  further comprising the step of processing said web substrate. 
   
   
     5. The process of  claim 4  further comprising the steps of:
 (l) providing a desired first characteristic of said processed web substrate; 
 (m) measuring an actual first characteristic of said processed web substrate at a first location of said processed web substrate; 
 (n) comparing said actual first characteristic of said processed web substrate with said desired first characteristic of said processed web substrate; 
 (o) adjusting said calender load profile according to said comparison of said actual first characteristic of said processed web substrate with said desired first characteristic of said processed web substrate. 
 
   
   
     6. The process of  claim 5  wherein said measurement of said actual first characteristic of said processed web substrate is provided in at least a second location of said processed web substrate. 
   
   
     7. The process of  claim 5  wherein said adjusted calender load profile is provided as step (b). 
   
   
     8. The process of  claim 5  wherein said first characteristic of said processed web substrate is selected from the group consisting of caliper, machine direction stretch, cross-machine direction stretch, in-wound tension, compressive modulus, radial pressure, machine direction modulus, cross-machine direction modulus, cross-machine direction width, sheet length, roll firmness, roll compressibility, roll diameter, converted roll hardness, and combinations thereof. 
   
   
     9. The process of  claim 1  further comprising the steps of:
 (l) providing a desired second characteristic of said convolutely wound product; 
 (m) measuring an actual second characteristic of said convolutely wound product; 
 (n) comparing said actual second characteristic of said convolutely wound product with said desired second characteristic of said convolutely wound product; 
 (o) adjusting said nip load profile according to said comparison of said actual second characteristic of said convolutely wound product with said desired second characteristic of said convolutely wound product. 
 
   
   
     10. The process of  claim 9  wherein said adjusted nip load profile is provided as step (a). 
   
   
     11. The process of  claim 1  wherein said convolutely wound product is selected from the group consisting of paper products, plastics, non-woven materials, foams, foils, films, wire, string, sheet metal, and combinations thereof. 
   
   
     12. The process of  claim 1  wherein said calender load profile adjusts the displacement of a first roll in a calender system relative to a second roll in said calender system. 
   
   
     13. The process of  claim 1  wherein said nip load profile adjusts the displacement of a first roll in a web substrate winding system relative to said web substrate. 
   
   
     14. The process of  claim 1  wherein said calender load profile adjusts the force applied by a first roll in a calender system relative to a second roll in said calender system. 
   
   
     15. The process of  claim 1  wherein said nip load profile adjusts the force applied by a first roll in a web substrate winding system relative to said web substrate. 
   
   
     16. The process of  claim 1  wherein said property of said web substrate has at least a z-direction component. 
   
   
     17. The process of  claim 1  wherein said first physical characteristic of said web substrate is selected from the group consisting of caliper, machine direction stretch, cross-machine direction stretch, compressive modulus, machine direction modulus, cross-machine direction modulus, cross-machine direction width, and combinations thereof. 
   
   
     18. The process of  claim 1  wherein said second physical characteristic is selected from the group consisting of parent roll hardness, parent roll density, in-wound tension, radial pressure and combinations thereof. 
   
   
     19. The process of  claim 1  wherein said actual first physical characteristic is measured in at least two desired locations. 
   
   
     20. The process of  claim 1  wherein said step (f) occurs during said step (e).